Semiconductor device having a corner spacer

ABSTRACT

A device includes a fin protruding from a semiconductor substrate; a gate stack over and along a sidewall of the fin; a gate spacer along a sidewall of the gate stack and along the sidewall of the fin; an epitaxial source/drain region in the fin and adjacent the gate spacer; and a corner spacer between the gate stack and the gate spacer, wherein the corner spacer extends along the sidewall of the fin, wherein a first region between the gate stack and the sidewall of the fin is free of the corner spacer, wherein a second region between the gate stack and the gate spacer is free of the corner spacer.

PRIORITY CLAIM AND CROSS-REFERENCE

This application claims the benefit of U.S. Provisional Application No.63/025,332, filed on May 15, 2020, which application is herebyincorporated herein by reference.

BACKGROUND

Semiconductor devices are used in a variety of electronic applications,such as, for example, personal computers, cell phones, digital cameras,and other electronic equipment. Semiconductor devices are typicallyfabricated by sequentially depositing insulating or dielectric layers,conductive layers, and semiconductor layers of material over asemiconductor substrate, and patterning the various material layersusing lithography to form circuit components and elements thereon.

The semiconductor industry continues to improve the integration densityof various electronic components (e.g., transistors, diodes, resistors,capacitors, etc.) by continual reductions in minimum feature size, whichallow more components to be integrated into a given area.

BRIEF DESCRIPTION OF THE DRAWINGS

Aspects of the present disclosure are best understood from the followingdetailed description when read with the accompanying figures. It isnoted that, in accordance with the standard practice in the industry,various features are not drawn to scale. In fact, the dimensions of thevarious features may be arbitrarily increased or reduced for clarity ofdiscussion.

FIG. 1 illustrates an example of a FinFET in a three-dimensional view,in accordance with some embodiments.

FIGS. 2, 3, 4, 5, 6, and 7 are cross-sectional views of intermediatestages in the manufacturing of FinFETs, in accordance with someembodiments.

FIGS. 8A, 8B, 8C, 9A, 9B, 9C, 10A, 10B, 10C, 10D, 10E, 11A, 11B, 12A,12B, 13A, 13B, and 13C are various views of intermediate stages in themanufacturing of FinFETs, in accordance with some embodiments.

FIGS. 14A, 14B, and 14C are various views of an intermediate stage inthe deposition of a dielectric layer in the manufacturing of FinFETs, inaccordance with some embodiments.

FIGS. 15A, 15B, and 15C are cross-sectional views of an intermediatestage in the deposition of a dielectric layer in the manufacturing ofFinFETs, in accordance with some embodiments.

FIGS. 16A, 16B, and 16C are various views of an intermediate stage inthe formation of corner spacers in the manufacturing of FinFETs, inaccordance with some embodiments.

FIGS. 17A, 17B, 17C, and 17D are cross-sectional views of anintermediate stage in the deposition of a dielectric layer in themanufacturing of FinFETs, in accordance with some embodiments.

FIGS. 18A, 18B, 18C, 18D, 19A, 19B, 20A, and 20B are various views ofintermediate stages in the manufacturing of FinFETs, in accordance withsome embodiments.

FIGS. 21A, 21B, 21C, 22A, 22B, 22C, 23A, 23B, 23C, 24A, 24B, and 24C arevarious views of intermediate stages in the manufacturing of FinFETshaving corner spacers, in accordance with some embodiments.

DETAILED DESCRIPTION

The following disclosure provides many different embodiments, orexamples, for implementing different features of the invention. Specificexamples of components and arrangements are described below to simplifythe present disclosure. These are, of course, merely examples and arenot intended to be limiting. For example, the formation of a firstfeature over or on a second feature in the description that follows mayinclude embodiments in which the first and second features are formed indirect contact, and may also include embodiments in which additionalfeatures may be formed between the first and second features, such thatthe first and second features may not be in direct contact. In addition,the present disclosure may repeat reference numerals and/or letters inthe various examples. This repetition is for the purpose of simplicityand clarity and does not in itself dictate a relationship between thevarious embodiments and/or configurations discussed.

Further, spatially relative terms, such as “beneath,” “below,” “lower,”“above,” “upper” and the like, may be used herein for ease ofdescription to describe one element or feature's relationship to anotherelement(s) or feature(s) as illustrated in the figures. The spatiallyrelative terms are intended to encompass different orientations of thedevice in use or operation in addition to the orientation depicted inthe figures. The apparatus may be otherwise oriented (rotated 90 degreesor at other orientations) and the spatially relative descriptors usedherein may likewise be interpreted accordingly.

Various embodiments describe processes for forming spacers that separatethe corners of a replacement gate stack of a FinFET device from adjacentepitaxial source/drain regions. In some embodiments, after removing thedummy gate stack, a dielectric layer is deposited in the recess formedwhere the dummy gate stack was present. The dielectric layer is thenetched such that portions of the dielectric layer are left remaining incorner regions of the recess. These remaining portions of the dielectriclayer form “corner spacers” that block the replacement gate stack frombeing formed in the corner regions of the recess. The corner spacers arebetween the replacement gate stack and the epitaxial source/drainregions and thus increase the separation distance between thereplacement gate stack and the epitaxial source/drain regions. Thisincreased separation distance between the replacement gate stack and theepitaxial source/drain regions can reduce parasitic capacitance and/orleakage current between the replacement gate stack and the epitaxialsource/drain regions, and thus can improve the speed, performance,reliability, and/or yield of a FinFET device.

FIG. 1 illustrates an example of a FinFET in a three-dimensional view,in accordance with some embodiments. The FinFET comprises a fin 52 on asubstrate 50 (e.g., a semiconductor substrate). Isolation regions 56 aredisposed in the substrate 50, and the fin 52 protrudes above and frombetween neighboring isolation regions 56. Although the isolation regions56 are described/illustrated as being separate from the substrate 50, asused herein the term “substrate” may be used to refer to just thesemiconductor substrate or a semiconductor substrate inclusive ofisolation regions. Additionally, although the fin 52 is illustrated as asingle, continuous material as the substrate 50, the fin 52 and/or thesubstrate 50 may comprise a single material or a plurality of materials.In this context, the fin 52 refers to the portion extending between theneighboring isolation regions 56.

A gate dielectric layer 96 is along sidewalls and over a top surface ofthe fin 52, and a gate electrode 98 is over the gate dielectric layer96. Source/drain regions 82 are disposed in opposite sides of the fin 52with respect to the gate dielectric layer 96 and gate electrode 98. FIG.1 further illustrates reference cross-sections that are used in laterfigures. Cross-section A-A is along a longitudinal axis of the gateelectrode 98 and in a direction, for example, perpendicular to thedirection of current flow between the source/drain regions 82 of theFinFET. Cross-section B-B is perpendicular to cross-section A-A and isalong a longitudinal axis of the fin 52 and in a direction of, forexample, a current flow between the source/drain regions 82 of theFinFET. Cross-section D-D is parallel to cross-section A-A and extendsthrough a source/drain region 82 of the FinFET. Cross-section E-E isparallel to cross-section B-B and extends through the gate electrode 98of the FinFET. Subsequent figures refer to these referencecross-sections for clarity.

Some embodiments discussed herein are discussed in the context ofFinFETs formed using a gate-last process. In other embodiments, agate-first process may be used. Also, some embodiments contemplateaspects used in planar devices, such as planar FETs, nanostructure(e.g., nanosheet, nanowire, gate-all-around, or the like) field effecttransistors (NSFETs), or the like.

FIGS. 2 through 20B are cross-sectional views of intermediate stages inthe manufacturing of FinFETs, in accordance with some embodiments. FIGS.2 through 7 illustrate reference cross-section A-A illustrated in FIG. 1, except for multiple fins/FinFETs. FIGS. 8A, 9A, 10A, 11A, 12A, 13A,14A, 16A, 18A, 19A, and 20A are illustrated along referencecross-section A-A illustrated in FIG. 1 , and FIGS. 8B, 9B, 10B, 11B,12B, 13B, 14B, 16B, 18B, 18D, 19B, and 20B are illustrated along asimilar cross-section B-B illustrated in FIG. 1 , except for multiplefins/FinFETs. FIGS. 8C, 9C, 10C, 13C, 14C, 16C, 17A, 17B, 17C, 17D, and18C are illustrated as plan views at the cross-section C-C illustratedin FIGS. 8A and 8B. The cross-section C-C is a cross-section through thechannel region 58 and the epitaxial source/drain regions 82 (see FIGS.10A-E) of a fin 52, and is parallel to a major surface of the substrate50. FIGS. 10D and 10E are illustrated along reference cross-section D-Dillustrated in FIG. 1 , except for multiple fins/FinFETs. FIGS. 15A,15B, and 15C are illustrated along reference cross-section E-Eillustrated in FIG. 1 and FIG. 14C.

In FIG. 2 , a substrate 50 is provided. The substrate 50 may be asemiconductor substrate, such as a bulk semiconductor, asemiconductor-on-insulator (SOI) substrate, or the like, which may bedoped (e.g., with a p-type or an n-type dopant) or undoped. Thesubstrate 50 may be a wafer, such as a silicon wafer. Generally, an SOIsubstrate is a layer of a semiconductor material formed on an insulatorlayer. The insulator layer may be, for example, a buried oxide (BOX)layer, a silicon oxide layer, or the like. The insulator layer isprovided on a substrate, typically a silicon or glass substrate. Othersubstrates, such as a multi-layered or gradient substrate may also beused. In some embodiments, the semiconductor material of the substrate50 may include silicon; germanium; a compound semiconductor includingsilicon carbide, gallium arsenide, gallium phosphide, indium phosphide,indium arsenide, and/or indium antimonide; an alloy semiconductorincluding silicon-germanium, gallium arsenide phosphide, aluminum indiumarsenide, aluminum gallium arsenide, gallium indium arsenide, galliumindium phosphide, and/or gallium indium arsenide phosphide; orcombinations thereof.

The substrate 50 has an n-type region 50N and a p-type region 50P. Then-type region 50N can be for forming n-type devices, such as NMOStransistors, e.g., n-type FinFETs. The p-type region 50P can be forforming p-type devices, such as PMOS transistors, e.g., p-type FinFETs.The n-type region 50N may be physically separated from the p-type region50P (as illustrated by divider 51), and any number of device features(e.g., other active devices, doped regions, isolation structures, etc.)may be disposed between the n-type region 50N and the p-type region 50P.

In FIG. 3 , fins 52 are formed in the substrate 50. The fins 52 aresemiconductor strips. In some embodiments, the fins 52 may be formed inthe substrate 50 by etching trenches in the substrate 50. The etchingmay be any acceptable etch process, such as a reactive ion etch (RIE),neutral beam etch (NBE), the like, or a combination thereof. The etchmay be anisotropic.

The fins may be patterned by any suitable method. For example, the fins52 may be patterned using one or more photolithography processes,including double-patterning or multi-patterning processes. Generally,double-patterning or multi-patterning processes combine photolithographyand self-aligned processes, allowing patterns to be created that have,for example, pitches smaller than what is otherwise obtainable using asingle, direct photolithography process. For example, in one embodiment,a sacrificial layer is formed over a substrate and patterned using aphotolithography process. Spacers are formed alongside the patternedsacrificial layer using a self-aligned process. The sacrificial layer isthen removed, and the remaining spacers may then be used to pattern thefins. In some embodiments, the mask (or other layer) may remain on thefins 52.

In FIG. 4 , an insulation material 54 is formed over the substrate 50and between neighboring fins 52. The insulation material 54 may be anoxide, such as silicon oxide, a nitride, the like, or a combinationthereof, and may be formed by a high density plasma chemical vapordeposition (HDP-CVD), a flowable CVD (FCVD) (e.g., a CVD-based materialdeposition in a remote plasma system and post curing to make it convertto another material, such as an oxide), the like, or a combinationthereof. Other insulation materials formed by any acceptable process maybe used. In the illustrated embodiment, the insulation material 54 issilicon oxide formed by a FCVD process. An anneal process may beperformed once the insulation material is formed. In an embodiment, theinsulation material 54 is formed such that excess insulation material 54covers the fins 52. Although the insulation material 54 is illustratedas a single layer, some embodiments may utilize multiple layers. Forexample, in some embodiments a liner (not shown) may first be formedalong a surface of the substrate 50 and the fins 52. Thereafter, a fillmaterial, such as those discussed above may be formed over the liner.

In FIG. 5 , a removal process is applied to the insulation material 54to remove excess insulation material 54 over the fins 52. In someembodiments, a planarization process such as a chemical mechanicalpolish (CMP), an etch-back process, combinations thereof, or the likemay be utilized. The planarization process exposes the fins 52 such thattop surfaces of the fins 52 and the insulation material 54 are levelafter the planarization process is complete. In embodiments in which amask remains on the fins 52, the planarization process may expose themask or remove the mask such that top surfaces of the mask or the fins52, respectively, and the insulation material 54 are level after theplanarization process is complete.

In FIG. 6 , the insulation material 54 is recessed to form ShallowTrench Isolation (STI) regions 56. The insulation material 54 isrecessed such that upper portions of fins 52 in the n-type region 50Nand in the p-type region 50P protrude from between neighboring STIregions 56. Further, the top surfaces of the STI regions 56 may have aflat surface as illustrated, a convex surface, a concave surface (suchas dishing), or a combination thereof. The top surfaces of the STIregions 56 may be formed flat, convex, and/or concave by an appropriateetch. The STI regions 56 may be recessed using an acceptable etchingprocess, such as one that is selective to the material of the insulationmaterial 54 (e.g., etches the material of the insulation material 54 ata faster rate than the material of the fins 52). For example, an oxideremoval using, for example, dilute hydrofluoric (dHF) acid may be used.

The process described with respect to FIGS. 2 through 6 is just oneexample of how the fins 52 may be formed. In some embodiments, the finsmay be formed by an epitaxial growth process. For example, a dielectriclayer can be formed over a top surface of the substrate 50, and trenchescan be etched through the dielectric layer to expose the underlyingsubstrate 50. Homoepitaxial structures can be epitaxially grown in thetrenches, and the dielectric layer can be recessed such that thehomoepitaxial structures protrude from the dielectric layer to formfins. Additionally, in some embodiments, heteroepitaxial structures canbe used for the fins 52. For example, the fins 52 in FIG. 5 can berecessed, and a material different from the fins 52 may be epitaxiallygrown over the recessed fins 52. In such embodiments, the fins 52comprise the recessed material as well as the epitaxially grown materialdisposed over the recessed material. In an even further embodiment, adielectric layer can be formed over a top surface of the substrate 50,and trenches can be etched through the dielectric layer. Heteroepitaxialstructures can then be epitaxially grown in the trenches using amaterial different from the substrate 50, and the dielectric layer canbe recessed such that the heteroepitaxial structures protrude from thedielectric layer to form the fins 52. In some embodiments wherehomoepitaxial or heteroepitaxial structures are epitaxially grown, theepitaxially grown materials may be in situ doped during growth, whichmay obviate prior and subsequent implantations although in situ andimplantation doping may be used together.

Still further, it may be advantageous to epitaxially grow a material inn-type region 50N (e.g., an NMOS region) different from the material inp-type region 50P (e.g., a PMOS region). In various embodiments, upperportions of the fins 52 may be formed from silicon-germanium(Si_(x)Ge_(1-x), where x can be in the range of 0 to 1), siliconcarbide, pure or substantially pure germanium, a III-V compoundsemiconductor, a II-VI compound semiconductor, or the like. For example,the available materials for forming III-V compound semiconductorinclude, but are not limited to, indium arsenide, aluminum arsenide,gallium arsenide, indium phosphide, gallium nitride, indium galliumarsenide, indium aluminum arsenide, gallium antimonide, aluminumantimonide, aluminum phosphide, gallium phosphide, and the like.

Further in FIG. 6 , appropriate wells (not shown) may be formed in thefins 52 and/or the substrate 50. In some embodiments, a P well may beformed in the n-type region 50N, and an N well may be formed in thep-type region 50P. In some embodiments, a P well or an N well are formedin both the n-type region 50N and the p-type region 50P.

In the embodiments with different well types, the different implantsteps for the n-type region 50N and the p-type region 50P may beachieved using a photoresist and/or other masks (not shown). Forexample, a photoresist may be formed over the fins 52 and the STIregions 56 in the n-type region 50N. The photoresist is patterned toexpose the p-type region 50P of the substrate 50. The photoresist can beformed by using a spin-on technique and can be patterned usingacceptable photolithography techniques. Once the photoresist ispatterned, an n-type impurity implant is performed in the p-type region50P, and the photoresist may act as a mask to substantially preventn-type impurities from being implanted into the n-type region 50N. Then-type impurities may be phosphorus, arsenic, antimony, or the likeimplanted in the region to a concentration of equal to or less than 10¹⁸cm⁻³, such as between about 10¹⁶ cm⁻³ and about 10¹⁸ cm⁻³. After theimplant, the photoresist is removed, such as by an acceptable ashingprocess.

Following the implanting of the p-type region 50P, a photoresist isformed over the fins 52 and the STI regions 56 in the p-type region 50P.The photoresist is patterned to expose the n-type region 50N of thesubstrate 50. The photoresist can be formed by using a spin-on techniqueand can be patterned using acceptable photolithography techniques. Oncethe photoresist is patterned, a p-type impurity implant may be performedin the n-type region 50N, and the photoresist may act as a mask tosubstantially prevent p-type impurities from being implanted into thep-type region 50P. The p-type impurities may be boron, boron fluoride,indium, or the like implanted in the region to a concentration of equalto or less than 10¹⁸ cm⁻³, such as between about 10¹⁶ cm⁻³ and about10¹⁸ cm⁻³. After the implant, the photoresist may be removed, such as byan acceptable ashing process.

After the implants of the n-type region 50N and the p-type region 50P,an anneal may be performed to repair implant damage and to activate thep-type and/or n-type impurities that were implanted. In someembodiments, the grown materials of epitaxial fins may be in situ dopedduring growth, which may obviate the implantations, although in situ andimplantation doping may be used together.

In FIG. 7 , a dummy dielectric layer 60 is formed on the fins 52. Thedummy dielectric layer 60 may be, for example, silicon oxide, siliconnitride, a combination thereof, or the like, and may be deposited orthermally grown according to acceptable techniques. A dummy gate layer62 is formed over the dummy dielectric layer 60, and a mask layer 64 isformed over the dummy gate layer 62. The dummy gate layer 62 may bedeposited over the dummy dielectric layer 60 and then planarized, suchas by a CMP. The mask layer 64 may be deposited over the dummy gatelayer 62. The dummy gate layer 62 may be a conductive or non-conductivematerial and may be selected from a group including amorphous silicon,polycrystalline-silicon (polysilicon), polycrystalline silicon-germanium(poly-SiGe), metallic nitrides, metallic silicides, metallic oxides, andmetals. The dummy gate layer 62 may be deposited by physical vapordeposition (PVD), CVD, sputter deposition, or other techniques fordepositing the selected material. The dummy gate layer 62 may be made ofother materials that have a high etching selectivity from the etching ofisolation regions, e.g., the STI regions 56 and/or the dummy dielectriclayer 60. The mask layer 64 may include one or more layers of, forexample, silicon nitride, silicon oxynitride, or the like. In thisexample, a single dummy gate layer 62 and a single mask layer 64 areformed across the n-type region 50N and the p-type region 50P. It isnoted that the dummy dielectric layer 60 is shown covering only the fins52 for illustrative purposes only. In some embodiments, the dummydielectric layer 60 may be deposited such that the dummy dielectriclayer 60 covers the STI regions 56, extending over the STI regions andbetween the dummy gate layer 62 and the STI regions 56.

FIGS. 8A through 20B illustrate various additional steps in themanufacturing of embodiment devices. FIGS. 8A through 20B illustratefeatures in either of the n-type region 50N and the p-type region 50P.For example, the structures illustrated in FIGS. 8A through 20B may beapplicable to both the n-type region 50N and the p-type region 50P.Differences (if any) in the structures of the n-type region 50N and thep-type region 50P are described in the text accompanying each figure.FIGS. 8C, 9C, 10C, 13C, 14C, 16C, 17A, 17B, 17C, 17D, and 18C areillustrated as plan views through the structure at the cross-section C-Cillustrated in FIGS. 8A and 8B. Note that the cross-section C-C shown inFIGS. 8A and 8B is below the top surface of the channel regions 58 ofthe fins 52.

In FIGS. 8A, 8B, and 8C, the mask layer 64 (see FIG. 7 ) may bepatterned using acceptable photolithography and etching techniques toform masks 74. The pattern of the masks 74 then may be transferred tothe dummy gate layer 62. In some embodiments (not illustrated), thepattern of the masks 74 may also be transferred to the dummy dielectriclayer 60 by an acceptable etching technique to form dummy gates 72. Thedummy gates 72 cover respective channel regions 58 of the fins 52. Thepattern of the masks 74 may be used to physically separate each of thedummy gates 72 from adjacent dummy gates. The dummy gates 72 may alsohave a lengthwise direction substantially perpendicular to thelengthwise direction of respective epitaxial fins 52.

Further in FIGS. 8A-C, gate seal spacers 80 can be formed on exposedsurfaces of the dummy gates 72, the masks 74, and/or the fins 52. Athermal oxidation or a deposition followed by an anisotropic etch mayform the gate seal spacers 80. The gate seal spacers 80 may be formed ofsilicon oxide, silicon nitride, silicon oxynitride, or the like.

Referring to FIG. 8C, in some embodiments, the masks 74 or dummy gates72 may have a flared profile near the fins 52. In some cases, the flaredprofile may be due to topography or loading that affects thephotolithography and/or etching steps that form the masks 74 or dummygates 72. For example, in some cases, a dummy gate 72 having an aspectratio (height:width) of about 4:1 or greater may be more likely to beformed having a flared profile near the fins 52. The dummy gates 72 mayhave a flared profile such that they have a width W2 near the fins 52that is larger than a width W1 away from the fins 52. In someembodiments, regions of the dummy gates 72 that are away from the fins52 may have a width W1 that is between about 10 nm and about 30 nm. Insome embodiments, regions of the dummy gates 72 that are near the fins52 may have a width W2 that is between about 11 nm and about 40 nm. Thewidth W2 may be greater than the width W1 by a width W3 that is betweenabout 1 nm and about 10 nm. In some embodiments, the width W3 may be inthe range from about 10% to about 30% of the width W1. Other widths thanthese are possible, and the flared profile regions of the dummy gates 72may have a different shape or size than shown. In some embodiments, thephotolithography or etching steps are controlled to produce a desiredflared profile of the dummy gates 72 near the fins 52, such as byappropriate choice of the aspect ratio of the dummy gates 72. In someembodiments, portions of the dummy gates 72 formed on top surfaces ofthe fins 52 (e.g., as shown in FIG. 8B) do not have a flared profilenear the fins 52. In this manner, a dummy gate 72 may be formed having aflared profile near sidewalls of a fin 52 and not near a top surface ofthe fin 52. The portions of the dummy gates 72 formed on top surfaces ofthe fins 52 may have a width about the same as the width W1 or the widthW2, or may have a different width, such as a width between the widths W1and W2, or another width.

After the formation of the gate seal spacers 80, implants for lightlydoped source/drain (LDD) regions (not explicitly illustrated) may beperformed. In the embodiments with different device types, similar tothe implants discussed above in FIG. 6 , a mask, such as a photoresist,may be formed over the n-type region 50N, while exposing the p-typeregion 50P, and appropriate type (e.g., p-type) impurities may beimplanted into the exposed fins 52 in the p-type region 50P. The maskmay then be removed. Subsequently, a mask, such as a photoresist, may beformed over the p-type region 50P while exposing the n-type region 50N,and appropriate type impurities (e.g., n-type) may be implanted into theexposed fins 52 in the n-type region 50N. The mask may then be removed.The n-type impurities may be the any of the n-type impurities previouslydiscussed, and the p-type impurities may be the any of the p-typeimpurities previously discussed. The lightly doped source/drain regionsmay have a concentration of impurities in the range of about 10¹⁵ cm⁻³to about 10¹⁹ cm⁻³. An anneal may be used to repair implant damage andto activate the implanted impurities.

In FIGS. 9A, 9B, and 9C, gate spacers 86 are formed on the gate sealspacers 80 along sidewalls of the dummy gates 72 and the masks 74. Thegate spacers 86 may be formed by conformally depositing an insulatingmaterial and subsequently anisotropically etching the insulatingmaterial. The insulating material of the gate spacers 86 may be siliconoxide, silicon nitride, silicon oxynitride, silicon carbonitride, acombination thereof, or the like. The gate spacers 86 may be formed fromone layer of insulating material or from multiple layers of variousinsulating materials. The gate seal spacers 80 and the gate spacers 86may be collectively referred to as spacers 85. Referring to FIG. 9C, insome embodiments, the thickness S1 of the spacers 85 in regions that areaway from the fins 52 may be between about 15 Å and about 1100 Å. Insome embodiments, the thickness S2 of the spacers 85 in regions that arenear the fins 52 is between about 5 Å and about 1000 Å, which may bebetween about 10 Å and about 100 Å smaller than S1. In some embodiments,a ratio of the thicknesses S2:S1 is between about 1:1.1 and about 1:1.5.Other thicknesses or relative thicknesses are possible.

It is noted that the above disclosure generally describes a process offorming spacers and LDD regions. Other processes and sequences may beused. For example, fewer or additional spacers may be utilized or adifferent sequence of steps may be utilized (e.g., the gate seal spacers80 may not be etched prior to forming the gate spacers 86, yielding“L-shaped” gate seal spacers, spacers may be formed and removed, and/orthe like). Furthermore, the n-type and p-type devices may be formedusing a different structures and steps. For example, LDD regions forn-type devices may be formed prior to forming the gate seal spacers 80while the LDD regions for p-type devices may be formed after forming thegate seal spacers 80.

In FIGS. 10A, 10B, and 10C, epitaxial source/drain regions 82 are formedin the fins 52. The epitaxial source/drain regions 82 are formed in thefins 52 such that each dummy gate 72 is disposed between respectiveneighboring pairs of the epitaxial source/drain regions 82. In someembodiments the epitaxial source/drain regions 82 may extend into, andmay also penetrate through, the fins 52. In some embodiments, the gatespacers 86 are used to separate the epitaxial source/drain regions 82from the dummy gates 72 by an appropriate lateral distance so that theepitaxial source/drain regions 82 do not short out subsequently formedgates of the resulting FinFETs. In some embodiments, the epitaxialsource/drain regions 82 may extend under the gate spacers 86, as shownin FIGS. 10B-C. A material of the epitaxial source/drain regions 82 maybe selected to exert stress in the respective channel regions 58,thereby improving performance.

The epitaxial source/drain regions 82 in the n-type region 50N may beformed by masking the p-type region 50P and etching source/drain regionsof the fins 52 in the n-type region 50N to form recesses in the fins 52.Then, the epitaxial source/drain regions 82 in the n-type region 50N areepitaxially grown in the recesses. The epitaxial source/drain regions 82may include any acceptable material, such as appropriate for n-typeFinFETs. For example, if the fin 52 is silicon, the epitaxialsource/drain regions 82 in the n-type region 50N may include materialsexerting a tensile strain in the channel region 58, such as silicon,silicon carbide, phosphorous doped silicon carbide, silicon phosphide,or the like. The epitaxial source/drain regions 82 in the n-type region50N may have surfaces raised from respective surfaces of the fins 52 andmay have facets.

The epitaxial source/drain regions 82 in the p-type region 50P may beformed by masking the n-type region 50N and etching source/drain regionsof the fins 52 in the p-type region 50P to form recesses in the fins 52.Then, the epitaxial source/drain regions 82 in the p-type region 50P areepitaxially grown in the recesses. The epitaxial source/drain regions 82may include any acceptable material, such as appropriate for p-typeFinFETs. For example, if the fin 52 is silicon, the epitaxialsource/drain regions 82 in the p-type region 50P may comprise materialsexerting a compressive strain in the channel region 58, such assilicon-germanium, boron doped silicon-germanium, germanium, germaniumtin, or the like. The epitaxial source/drain regions 82 in the p-typeregion 50P may have surfaces raised from respective surfaces of the fins52 and may have facets.

The epitaxial source/drain regions 82 and/or the fins 52 may beimplanted with dopants to form source/drain regions, similar to theprocess previously discussed for forming lightly-doped source/drainregions, followed by an anneal. The source/drain regions may have animpurity concentration of between about 10¹⁹ cm⁻³ and about 10²¹ cm⁻³.The n-type and/or p-type impurities for source/drain regions may be anyof the impurities previously discussed. In some embodiments, theepitaxial source/drain regions 82 may be in situ doped during growth.

FIGS. 10D and 10E illustrate cross-sections of a FinFET along referencecross-section D-D. As a result of the epitaxy processes used to form theepitaxial source/drain regions 82 in the n-type region 50N and thep-type region 50P, upper surfaces of the epitaxial source/drain regionshave facets which expand laterally outward beyond sidewalls of the fins52. In some embodiments, these facets cause adjacent source/drainregions 82 of a same FinFET to merge, as illustrated by FIG. 10D. Inother embodiments, adjacent source/drain regions 82 remain separatedafter the epitaxy process is completed as illustrated by FIG. 10D. Inthe embodiments illustrated in FIGS. 10C and 10D, gate spacers 86 areformed covering a portion of the sidewalls of the fins 52 that extendabove the STI regions 56 thereby blocking the epitaxial growth. In someother embodiments, the spacer etch used to form the gate spacers 86 maybe adjusted to remove the spacer material to allow the epitaxially grownregion to extend to the surface of the STI region 56.

In FIGS. 11A and 11B, a first interlayer dielectric (ILD) 88 isdeposited over the structure illustrated in FIGS. 10A and 10B. The firstILD 88 may be formed of a dielectric material, and may be deposited byany suitable method, such as CVD, plasma-enhanced CVD (PECVD), or FCVD.Dielectric materials may include phospho-silicate glass (PSG),boro-silicate glass (BSG), boron-doped phospho-silicate glass (BPSG),undoped silicate glass (USG), or the like. Other insulation materialsformed by any acceptable process may be used. In some embodiments, acontact etch stop layer (CESL) 87 is disposed between the first ILD 88and the epitaxial source/drain regions 82, the masks 74, and the gatespacers 86. The CESL 87 may comprise a dielectric material, such as,silicon nitride, silicon oxide, silicon oxynitride, or the like, havinga lower etch rate than the material of the overlying first ILD 88.

In FIGS. 12A and 12B, a planarization process, such as a CMP, may beperformed to level the top surface of the first ILD 88 with the topsurfaces of the dummy gates 72 or the masks 74. The planarizationprocess may also remove the masks 74 on the dummy gates 72, and mayremove portions of the gate seal spacers 80 and the gate spacers 86along sidewalls of the masks 74. After the planarization process, topsurfaces of the dummy gates 72, the gate seal spacers 80, the gatespacers 86, and the first ILD 88 may be level. Accordingly, the topsurfaces of the dummy gates 72 are exposed through the first ILD 88. Insome embodiments, the masks 74 may remain, in which case theplanarization process levels the top surface of the first ILD 88 withthe top surfaces of the masks 74.

In FIGS. 13A, 13B, and 13C, the dummy gates 72 and the masks 74 (ifpresent) are removed in an etching step(s), so that recesses 90 areformed. FIGS. 13A-B illustrate cross-sectional views along the referencecross-sections A-A and B-B, respectively. FIG. 13C illustrates a sectionthrough the channel region 58 and the epitaxial source/drain regions 82in a plan view along the reference cross-section C-C as shown in FIGS.13A-B. In some embodiments, the dummy gates 72 are removed, and thedummy dielectric layer 60 remains and is exposed by the recesses 90. Insome embodiments, the recess 90 is laterally bounded by the dummydielectric layer 60 and the spacers 85. Each recess 90 overlies achannel region 58 of a respective fin 52, which is disposed betweenneighboring pairs of the epitaxial source/drain regions 82. During theremoval, the dummy dielectric layer 60 may be used as an etch stop layerwhen the dummy gates 72 are etched.

In some embodiments, the flared profile of the dummy gates 72 near thefins 52 results in the recesses 90 having a flared profile near the fins52 as illustrated in FIG. 13C. For example, regions of the recesses 90near the fins 52 may have a width W5 that is larger than a width W4 ofregions of the recesses 90 away from the fins 52. In some embodiments,regions of the recesses 90 that are away from the fins 52 may have awidth W4 that is about the same as the width W1 (see FIG. 8C). In someembodiments, regions of the recesses 90 that are near the fins 52 mayhave a width W5 that is between about 100 Å and about 300 Å, which maybe between about 1 Å and about 1200 Å greater than the width W3. In thismanner, the recesses 90 may have corner regions 91 adjacent the fins 52that protrude laterally relative to regions of the recesses 90 that areaway from the fins 52. The recesses 90 may extend closer to theepitaxial source/drain regions 82 than regions of the recesses 90 thatare away from the fins 52. Example corner regions 91 are indicated inFIG. 13C.

In some embodiments, the corner regions 91 may protrude a distance D1along the fins 52 that is between about 0.5 Å and about 600 Å, and mayextend a distance D2 perpendicular to the fins 52 that is between about0.5 Å and about 600 Å. Other distances are possible. In otherembodiments, the corner regions 91 may have a different shape or sizethan shown in FIG. 13C. For example, the sidewalls of the spacers 85 atthe corner regions 91 may be straight, curved, concave, convex,irregular, etc.

In some embodiments, the dummy gates 72 are removed by an anisotropicdry etch process. The anisotropic dry etching process may include usingreaction gas(es) that selectively etch the dummy gates 72 withoutsignificantly etching the first ILD 88 or the gate spacers 86. In someembodiments, the anisotropic dry etching process includes generating aplasma with a power between about 10 Watts and about 1000 Watts. Theanisotropic dry etching process may be performed at a pressure betweenabout 5 mTorr and about 500 mTorr and at a process temperature betweenabout 40° C. and about 100° C. The anisotropic dry etching process mayinclude a bias power between about 10 Watts and about 800 Watts. In someembodiments, the anisotropic dry etching process may use one or moreprocess gases such as HBr, Cl₂, H₂, N₂, O₂, C_(x)F_(y), CH_(x)F_(y), thelike, or combinations thereof. For example, in some embodiments, theanisotropic etching process includes flowing HBr at a flow rate betweenabout 10 sccm and about 500 sccm, flowing Cl₂ at a flow rate betweenabout 10 sccm and about 200 sccm, flowing He at a flow rate betweenabout 50 sccm and about 1000 sccm, flowing CF₄ at a flow rate betweenabout 1 sccm and about 50 sccm, flowing CH₂F₂ at a flow rate betweenabout 5 sccm and about 20 sccm, and/or flowing O₂ at a flow rate betweenabout 5 sccm and about 20 sccm. Other process gases or processconditions are possible.

In FIGS. 14A, 14B, and 14C, a dielectric layer 92 is deposited over thestructure and within the recesses 90, in accordance with someembodiments. The dielectric layer 92 may be deposited as a conformallayer that extends over the STI regions 56, the ILD 88, the CESL 87, thegate seal spacers 80, and the gate spacers 86. The dielectric layer 92may extend along sidewalls of the recesses 90 and over the dummydielectric layer 60 within the recesses 90. In FIG. 14C, portions of thedielectric layer 92 deposited on sidewalls are indicated as dielectriclayer 92, and portions deposited on top surfaces (e.g., lateralsurfaces) are indicated as dielectric layer 92′. In some embodiments,the dielectric layer 92 is formed having a thickness T1 on the topsurfaces of the dummy dielectric layer 60 within the recesses 90 that isbetween about 0.5 Å and about 300 Å. The dielectric layer 92 may have athickness T2 on sidewalls of the dummy dielectric layer 60 that isbetween about 0.5 Å and about 300 Å. In some embodiments, the dielectriclayer 92 is formed on sidewalls of the gate spacers 85 having athickness T3 that is between about 0.5 Å and about 300 Å. Thethicknesses T1, T2, and/or T3 may be similar thicknesses or may bedifferent thicknesses. As shown in FIG. 14C, the dielectric layer 92fills or partially fills the corner regions 91 of the recesses 90.Filling the corner regions 91 with the dielectric layer 92 allows forthe formation of corner spacers 94, which are described in greaterdetail for FIGS. 16A-C. As such, the amount of dielectric layer 92material that is deposited may be based on the size of the cornerregions 91. In some embodiments, the dielectric layer 92 laterally fillsthe corner regions 91 to a thickness T4 measured from the corner of thecorner regions 91. The thickness T4 may be between about 0.5 Å and about600 Å, and may be greater than, less than, or about the same as thedistance D1 (see FIG. 13C). Other thicknesses are possible.

The dielectric layer 92 may be formed having a substantially uniformthickness along a surface or may be formed having a varying thicknesseson along a surface. For example, the dielectric layer 92 may be formedhaving a thickness profile on sidewalls of the recess 90 which isuniform or which varies, such as being thickest near the top of therecess 90 or thickest near the bottom of the recess 90. Other thicknessprofiles are possible, such as forming a dielectric layer 92 that hasvertical surfaces, angled surfaces, straight surfaces, curved surfaces,convex surfaces, concave surfaces, irregular surfaces, etc. In someembodiments, the thickness profile of the dielectric layer 92 iscontrolled by controlling parameters or characteristics of thedeposition process. For example, a more conformal deposition process mayproduce a thickness profile similar to that shown in FIG. 15A (describedin greater detail below), or a less conformal deposition process mayproduce a thickness profile similar to that shown in FIG. 15B or 15C(described in greater detail below). In some embodiments, the thicknessprofile of the dielectric layer 92 may be controlled, for example, toensure that the corner regions 91 are completely filled, or tofacilitate formation of corner spacers 94 (see FIG. 16C) having adesired size, shape, or thickness profile. The formation of cornerspacers 94 with particular thickness profiles is discussed in greaterdetail below for FIG. 16C.

As examples, FIGS. 15A, 15B, and 15C illustrate dielectric layers 92having different thickness profiles, in accordance with someembodiments. FIGS. 15A-C illustrate cross-sectional views along thereference cross-section E-E indicated in FIG. 1 and FIG. 14C. FIG. 15Ashows a dielectric layer 92 having a substantially uniform thickness onthe bottom and the sidewalls of the recess 90, similar to the dielectriclayer 92 shown in FIGS. 14A-C. For example, the dielectric layer 92shown in FIG. 15A may have a substantially uniform thickness T1 on thedummy dielectric layer 60 and a substantially uniform thickness T3 onsidewalls of the gate spacers 85. The thicknesses T1 and T3 may besimilar or different thicknesses.

FIG. 15B illustrates a dielectric layer 92 having a thickness profilesuch that the dielectric layer 92 has a greater thickness near thebottom of the recess 90 and a smaller thickness near the top of therecess 90. For example, the dielectric layer 92 may have a top thicknessT3T near the top of the recess 90 that is smaller than a bottomthickness T3B near the bottom of the recess 90. In some embodiments, thetop thickness T3T may be between about 5% and about 95% of the bottomthickness T3B. In some embodiments, the dielectric layer 92 may have athickness T1 on the dummy dielectric layer 60 that is greater than thetop thickness T3T, and which may be similar to the bottom thickness T3B.Other relative thicknesses are possible.

FIG. 15C illustrates a dielectric layer 92 having a thickness profilesuch that the dielectric layer 92 has a greater thickness near the topof the recess 90 and a smaller thickness near the bottom of the recess90. For example, the dielectric layer 92 may have a top thickness T3Tnear the top of the recess 90 that is greater than a bottom thicknessT3B near the bottom of the recess 90. In some embodiments, the bottomthickness T3B may be between about 5% and about 95% of the top thicknessT3T. In some embodiments, the dielectric layer 92 may have a thicknessT1 on the dummy dielectric layer 60 that is smaller than the topthickness T3T, and which may be similar to the bottom thickness T3B.Other relative thicknesses are possible.

The dielectric layer 92 may be a dielectric material, such as an oxide,a nitride, or the like. In some embodiments, the dielectric material isa silicon-based material, such as silicon oxide, silicon carbide,silicon oxycarbide, silicon oxynitride, silicon oxycarbonitride, or thelike. Other dielectric materials are possible. In some embodiments, thedielectric layer 92 includes multiple layers of different dielectricmaterials. In some embodiments, the dielectric layer 92 is a materialwhich may be selectively etched over the materials of other features,such as the gate spacers 85, the channel region 58, The dielectric layer92 may be deposited using a suitable deposition process, such as CVD,PECVD, PVD, ALD, the like, or combinations thereof.

In FIGS. 16A, 16B, and 16C, an etching process is performed to etch thedielectric layer 92 and form corner spacers 94, in accordance with someembodiments. The etching process removes the dielectric layer 92 fromthe bottom surfaces and the sidewall surfaces of the recesses 90, butincompletely etches the dielectric layer 92 in and near the cornerregions 91, in some embodiments. The etching process may also remove thedielectric layer 92 from top surfaces of the STI regions 56, the ILD 88,the CESL 87, the gate seal spacers 80, and/or the gate spacers 86. Inthis manner, portions of the dielectric layer 92 are left remaining inthe corner regions 91 after performing the etching process. In somecases, the narrow geometry of the corner regions 91 and/or therelatively thicker dielectric layer 92 within the corner regions 91 mayallow for a slower etch rate of the dielectric layer 92 near the cornerregions 91 than away from the corner regions 91. In some embodiments,the etching process may be controlled to halt etching after portions ofthe dielectric layer 92 away from the corner regions 91 have beenremoved but before portions of the dielectric layer 92 near the cornerregions 91 have been removed. In this manner, the dielectric layer 92within the corner regions 91 may be incompletely etched. The remainingportions of the dielectric layer 92 partially or completely fill thecorner regions 91, and are referred to herein as corner spacers 94. Insome embodiments, the etching process may also etch through the dummydielectric layer 60 to expose the channel region 58, as shown in FIGS.16A-C.

As shown in FIG. 16C, the corner spacers 94 cover portions of thespacers 85 and/or the dummy dielectric layer 60 near the corner regions91. Each corner spacer 94 has a sidewall 95 that extends from a gatespacer 85 to the dummy dielectric layer 60. In some embodiments, thecorner spacers 94 may extend along the fins 52 (e.g., along the dummydielectric layer 60) a distance T5 that is between about 0.5 Å and about600 Å, and may extend perpendicular to the fins 52 (e.g., along the gatespacers 85) a distance T6 between about 0.5 Å and about 600 Å. In someembodiments, the distance T5 is greater than the distance D1 (see FIG.13C) of the corner regions 91, but may be about the same as or less thanthe distance D1 in other embodiments. The distance T6 may be greaterthan, about the same as, or less than the distance D2 (see FIG. 13C) ofthe corner regions 91. Other distances are possible. In someembodiments, the sidewall 95 may have an angle A1 with the dummydielectric layer 60 that is between about 10° and about 90°.

In some embodiments, the corner spacers 94 have a substantially uniformsize (e.g., distances T5, distance T6, and/or cross-sectional area) or asubstantially uniform shape along a vertical direction from the near thetop of the recess 90 to near the bottom of the recess 90. In otherembodiments, the corner spacers 94 may have varying size, shape, orcross-sectional area along a vertical direction. For example, in someembodiments, depositing a dielectric layer 92 that has a greaterthickness near the bottom of the recess 90, such as shown in FIG. 15B,may allow the formation of corner spacers 94 that have a larger sizenear the top of the recess 90 than near the bottom of the recess 90.Similarly, depositing a dielectric layer 92 that has a greater thicknessnear the bottom of the recess 90, such as shown in FIG. 15C, may allowthe formation of corner spacers 94 that have a larger size (e.g.,greater distances T5 and/or T6) near the bottom of the recess 90 thannear the top of the recess 90. In this manner, the separation distanceS3 between a gate electrode 98 and an epitaxial source/drain regions 82(see FIG. 18C) may be controlled to be different distances at differentlocations along a vertical direction, which can allow for greatercontrol of the capacitance between the gate electrode 98 and theepitaxial source/drain region 82, described in greater detail below.

FIG. 16C illustrates the corner spacers 94 as having an approximatelytriangular shape with a straight sidewall 95, but the corner spacers 94may be formed having other shapes. For example, the sidewall 95 may havea curved shape, a convex shape, a concave shape, an irregular shape, thelike, or a combination thereof. Some examples of corner spacers 94having different shapes are described below for FIGS. 17A-D. The shapeof the corner spacers 94 may be controlled by controlling the shape ofthe corner regions 91, the thickness of the dielectric layer 92, and/orthe parameters of the etching process that etches the dielectric layer92. In some cases, the shape of the sidewall 95 may be controlled tocontrol the separation distance S3 or to control the shape of the gatedielectric layer 96 and gate electrode 98 (see FIG. 18C). For example, aconvex sidewall 95 may increase the separation distance S3.

In some embodiments, the etching process that etches the dielectriclayer 92 and forms the corner spacers 94 includes one or more dryetching processes, one or more wet etching processes, or a combinationthereof. For example, the etching process may include a plasma etchingprocess, which may be an isotropic etching process, an anisotropicetching process, or a combination thereof. In some embodiments, theplasma etching process includes using reaction gas(es) that selectivelyetch the dielectric layer 92 over other features such as the first ILD88, the gate seal spacers 80, the gate spacers 86, etc. In someembodiments, the plasma etching process is performed in a processingchamber with process gases being supplied into the processing chamber.The process gases may include single gases or mixtures of gases. Theprocess gases may include CF₄, C₂F₆, CH₃F, C₄F₆, CHF₃, CH₂F₂, Cl₂, C₄H₆,BCl₃, SiCl₄, SF₆, HBr, H₂, NF₃, the like, other gases, or combinationsthereof. In some embodiments, the process gases may include other gasesused to control the selectivity of the plasma etching process, such asO₂, CO₂, SO₂, CO, SiCl₄, N₂, the like, other gases, or combinationsthereof. For example, in some cases, increasing the amount of O₂ withinthe process gases can increase the selectivity of the plasma etchingprocess over silicon oxide. The process gases may also include carriergases such as Ar, He, Ne, Xe, the like, or combinations thereof.

The process gases may be flowed into the processing chamber at a ratebetween about 10 sccm and about 5000 sccm. The plasma etching processmay performed using a bias power between about 0 Watts and about 3000Watts, and having a plasma power between about 10 Watts and about 3000Watts. The plasma etching process may be performed at a temperaturebetween about 40° C. and about 100° C. A pressure in the processingchamber may be between about 1 mTorr and about 10 Torr. Other processconditions are possible. In some embodiments, the plasma is a directplasma. In other embodiments, the plasma is a remote plasma that isgenerated in a separate plasma generation chamber connected to theprocessing chamber. Process gases may be activated into plasma by anysuitable method of generating the plasma, such as using a transformercoupled plasma generator, inductively coupled plasma (ICP) systems,magnetically enhanced reactive ion techniques, electron cyclotronresonance techniques, or the like.

In some embodiments, the plasma etching process may include, forexample, an Atomic Layer Etching (ALE) process, an RIE process, oranother plasma process. For example, the plasma etching process may beperformed using a bias power between about 100 Watts and about 800Watts, and having a plasma power between about 10 Watts and about 500Watts. The plasma etching process may be performed at a temperaturebetween about 40° C. and about 100° C. A pressure in the processingchamber may be between about 5 mTorr and about 100 Torr. In someembodiments, the anisotropic etching process includes flowing HBr at aflow rate between about 10 sccm and about 500 sccm, flowing Cl₂ at aflow rate between about 10 sccm and about 200 sccm, flowing Ar at a flowrate between about 100 sccm and about 1000 sccm, flowing C₄F₆ at a flowrate between about 10 sccm and about 100 sccm, and/or flowing O₂ at aflow rate between about 10 sccm and about 100 sccm. Other process gasesor process conditions are possible.

The etching process may be performed in a single etching step or usingmultiple steps. In some embodiments, a first etching process is used toetch the dielectric layer 92 to expose the dummy dielectric layer 60 andform the corner spacers 94, and then a second etching process is used toetch the exposed portions of the dummy dielectric 60. In theseembodiments, the first etching process and/or the second etching processmay include a single etching step or multiple etching steps. FIGS. 16A-Cshow an embodiment in which the dummy dielectric layer 60 is etched, butin other embodiments, the dummy dielectric layer 60 is not etched andremains over the channel region 58. In some embodiments, the dielectriclayer 92 may be incompletely etched to form the corner spacers 94 bycontrolling the duration of time the etching process is performed. Forexample, the etching process (or a step of the etching process) may beperformed until the dielectric layer 92 is removed from sidewalls of thegate spacers 95 and from over the channel region 58 but halted beforethe dielectric layer 92 is fully removed from the corner regions 91.

In some embodiments, the corner spacers 94 may be formed in one regionof the substrate 50 using a separate etching process than is used toform the corner spacers 94 in another region of the substrate 50. Inthis manner, different regions may have corner spacers 94 of differentshapes or sizes, for example. In some embodiments, the dielectric layer92 may be etched in one region to form corner spacers 94, but thedielectric layer 92 may be completely removed in another region withoutforming corner spacers 94. In some embodiments, the dielectric layer 92may be etched in one region to form corner spacers 94, but in anotherregion the dielectric layer 92 is not etched and remains within therecesses 90. Various masking steps may be used to mask and exposeappropriate regions when using distinct processes such as thosedescribed. An example embodiment in which the dielectric layer 92 is notetched in a separate region is described below for FIGS. 21A-C throughFIGS. 24A-C.

Turning to FIGS. 17A-D, corner spacers 94 having different shapes areshown, in accordance with some embodiments. FIGS. 17A-D show a detailedview of the region 93 indicated in FIG. 16C. The shapes of cornerspacers 94 shown in FIGS. 17A-D or other shapes of corner spacers 94 maybe controlled by controlling the parameters or characteristics of theetching process, such as controlling the over-etching, the process gasflow rates, the plasma power, the bias power, or other parameters orcharacteristics. FIG. 17A illustrates an example corner spacer 94 havinga sidewall 95 that is concave and comprises substantially straightsections. In some cases, forming a corner spacer 94 with a concavesidewall 95 may allow for the formation of a larger gate electrode 98.The sidewall 95 may have an angle A1 with respect to the dummydielectric layer 60. In some embodiments, an end of the sidewall 95 maybe approximately flush with the gate spacer 85, as shown in FIG. 17A. Inother embodiments, an end of the sidewall 95 may have an angle withrespect to the gate spacer 85. FIG. 17B illustrates an example cornerspacer 94 having a sidewall 95 that is concave and curved. In someembodiments, increasing the bias power and/or increasing the amount ofover-etching by increasing the process time or the plasma power can forma corner spacer 94 having a more concave or curved sidewall. FIG. 17Cillustrates an example corner spacer 94 with a sidewall 95 that issubstantially flush with the spacer 85. In this manner, the cornerspacer 94 fills the corner region 91 but does not extend significantlyoutside of the corner region 91, and thus the corner spacer 94 has across-sectional area similar to that of the corner region 91. In someembodiments, increasing the amount of over-etching can form a cornerspacer 94 that extends less outside of the corner region 91 (e.g., formsa smaller corner spacer 94). In some embodiments, a corner spacer 94that is more flush with a sidewall of the gate spacers 85 (e.g., withthe gate seal spacers 80) by increasing the bias power of the etchingprocess. In other embodiments, the corner spacer 94 may incompletelyfill a corner region 91 or may protrude outside of a corner region 91.FIG. 17D illustrates an example corner spacer 94 having an irregularshape. As shown in FIG. 17D, a corner spacer 94 may have a sidewall 95that is approximately flush with the etched sidewall of the dummydielectric layer 60, which can allow for a larger separation distance S3(see FIG. 18C). The sidewall 95 shown in FIG. 17D includes a convexregion, which can also allow for a larger separation distance S3. Asdescribed below, a larger separation distance S3 can allow for reducedparasitic capacitance and improve device performance. In someembodiments, an irregular profile may be formed by controlling therelative strengths of the over-etching and the bias power. The cornerspacers 94 shown in FIG. 17A-D are examples. Corner spacers 94 and theirsidewalls 95 having other sizes or shapes are possible, and all suchvariations are considered within the scope of the present disclosure.

In FIGS. 18A, 18B, 18C, and 18D, gate dielectric layer 96 and gateelectrodes 98 are formed for replacement gates within the recesses 90,in accordance with some embodiments. FIG. 18D illustrates a detailedview of region 97 of FIG. 18B. Gate dielectric layer 96 may include oneor more layers deposited in the recesses 90, such as on top surfaces andthe sidewalls of the fins 52 (e.g., on the channel regions 58) and onsidewalls of the spacers 85. The gate dielectric layers 96 are alsodeposited on the sidewalls 95 of the corner spacers 94 and on the dummydielectric layer 60. The gate dielectric layer 96 may also be formed onthe top surface of the first ILD 88 (not shown in the figures). In someembodiments, the gate dielectric layer 96 comprise one or moredielectric layers, such as one or more layers of silicon oxide, siliconnitride, metal oxide, metal silicate, or the like. For example, in someembodiments, the gate dielectric layer 96 include an interfacial layerof silicon oxide formed by thermal or chemical oxidation and anoverlying high-k dielectric material, such as a metal oxide or asilicate of hafnium, aluminum, zirconium, lanthanum, manganese, barium,titanium, lead, and combinations thereof. The gate dielectric layer 96may include a dielectric layer having a k value greater than about 7.0.The formation methods of the gate dielectric layer 96 may includeMolecular-Beam Deposition (MBD), ALD, PECVD, and the like. Inembodiments where portions of the dummy dielectric layer 60 remain inthe recesses 90, the gate dielectric layer 96 may include a material ofthe dummy dielectric layer 60 (e.g., silicon oxide).

The gate electrodes 98 are deposited over the gate dielectric layer 96,respectively, and fill the remaining portions of the recesses 90. Thegate electrodes 98 may include a metal-containing material such astitanium nitride, titanium oxide, tantalum nitride, tantalum carbide,cobalt, ruthenium, aluminum, tungsten, combinations thereof, ormulti-layers thereof. For example, although a single layer gateelectrode 98 is illustrated in FIGS. 18B-C, the gate electrode 98 maycomprise any number of liner layers 98A, any number of work functiontuning layers 98B, and a fill material 98C as illustrated by FIG. 18D.After the filling of the recesses 90, a planarization process, such as aCMP, may be performed to remove the excess portions of the gatedielectric layer 96 and the material of the gate electrodes 98, whichexcess portions are over the top surface of the ILD 88. The remainingportions of material of the gate electrodes 98 and the gate dielectriclayer 96 thus form replacement gates of the resulting FinFETs. The gateelectrodes 98 and the gate dielectric layer 96 may be collectivelyreferred to as a “replacement gate,” a “gate structure,” or a “gatestack.” The gate and the gate stacks may extend along sidewalls of achannel region 58 of the fins 52.

Referring to FIG. 18C, the corner spacers 94 block the gate dielectriclayers 96 and the gate electrodes 98 from being deposited in at least aportion of the corner regions 91. Thus, the presence of the cornerspacers 94 increases the overall separation distance S3 between theepitaxial source/drain regions 82 and the gate electrode 98 near thecorner regions 91. For example, without the formation of the cornerspacers 94, the gate dielectric layer 96 would be deposited within thecorner regions 91, and the gate dielectric layer 96 would be separatedfrom the epitaxial source/drain regions 82 by a distance S4. In someembodiments, the distance S4 may be between about 10 Å and about 100 Å,though other distances are possible. Due to the corner spacers 94, thegate dielectric layer 96 is separated from the epitaxial source/drainregions 82 by a distance S5 that is larger than the distance S4. In someembodiments, the distance S5 may be between about 10 Å and about 700 Å.In some embodiments, the distance S5 may be between about 0.5 Å andabout 600 Å larger than the distance S4. Other distances or relativedistances are possible. In this manner, by forming the corner spacers94, the separation distance S3 between the epitaxial source/drainregions 82 and adjacent gate electrodes 98 may be increased. In someembodiments, the separation distance S3 may be between about 10 Å andabout 800 Å. In some embodiments, the use of corner spacers 94 asdescribed herein can increase the separation distance S3 between a gateelectrode 98 and an adjacent source/drain region 82 by between about 10Å and about 700 Å. Other distances or relative distances are possible.It will also be appreciated that the distances S3, S4, and/or S5 shownin FIG. 18C are intended as representative of relative distances betweenthe epitaxial source/drain regions 82 and the associated features. Forexample, the distances S3, S4, and/or S5 may represent minimumdistances, average distances, “effective” distances, approximatedistances, or the like.

In some embodiments, the presence of the corner spacers 94 causes thegate stack to be formed having rounded edges or chamfered edges near thecorner regions 91. For example, the gate stacks near the fins 52 may beshaped approximately like a rectangle with rounded corners (e.g., a“stadium” shape or oval shape) or approximately like a rectangle withchamfered corners. Other shapes of the gate stack are possible, anddepend on the particular shape(s) of the corner spacers 94. By etchingthe dielectric layer 92 to form corner spacers 94, the separationdistance S3 may be increased without significantly decreasing the sizeof the gate stacks, as might be the case if the dielectric layer 92remains unetched. The separation distance S3 may also depend on theparticular shape(s) of the corner spacers 94, and the shape or size ofthe corner spacer 94 may be controlled to control the separationdistance S3. For example, a corner spacer 94 formed having a convexsidewall 95 (e.g., such as shown in FIG. 17D, or the like) may allow fora larger separation distance S3 than a corner spacer 94 formed having aconcave sidewall 95 (e.g., such as shown in FIG. 17B, or the like).Forming a relatively larger corner spacer 94 can allow for a relativelylarger separation distance S3, and forming a relatively smaller cornerspacer 94 can allow for a relatively smaller separation distance S3. Insome cases, the particular shapes or sizes of the corner spacers 94 orthe gate stacks and the particular separation distance S3 may be formedas desired for a particular application, device, or structure.

In some cases, by forming corner spacers 94 that increase the separationdistance S3 between the gate electrodes 98 and the epitaxialsource/drain regions 82, device performance may be improved. Forexample, increasing the separation distance S3 can reduce parasiticcapacitance between the gate electrodes 98 and the epitaxialsource/drain regions 82, which can improve device speed. In some cases,increasing the separation distance S3 can reduce current leakage betweenthe gate stack and the epitaxial source/drain regions 82. Additionally,increasing the separation distance S3 can reduce the chance of shorts(e.g. due to conductive residue or the like) being formed between thegate stack and the epitaxial source/drain regions 82 during devicemanufacture. This can improve yield, process flexibility, and devicereliability.

The formation of the gate dielectric layer 96 in the n-type region 50Nand the p-type region 50P may occur simultaneously such that the gatedielectric layer 96 in each region are formed from the same materials,and the formation of the gate electrodes 98 may occur simultaneouslysuch that the gate electrodes 98 in each region are formed from the samematerials. In some embodiments, the gate dielectric layer 96 in eachregion may be formed by distinct processes, such that the gatedielectric layer 96 may be different materials, and/or the gateelectrodes 98 in each region may be formed by distinct processes, suchthat the gate electrodes 98 may be different materials. Various maskingsteps may be used to mask and expose appropriate regions when usingdistinct processes.

In FIGS. 19A and 19B, a gate mask 106 is formed over the gate stack(including a gate dielectric layer 96 and a corresponding gate electrode98), and the gate mask may be disposed between opposing portions of thegate spacers 86. In some embodiments, forming the gate mask 106 includesrecessing the gate stack so that a recess is formed directly over thegate stack and between opposing portions of gate spacers 86. A gate mask106 comprising one or more layers of dielectric material, such assilicon nitride, silicon oxynitride, or the like, is filled in therecess, followed by a planarization process to remove excess portions ofthe dielectric material extending over the first ILD 88.

As also illustrated in FIGS. 19A and 19B, a second ILD 108 is depositedover the first ILD 88. In some embodiments, the second ILD 108 is aflowable film formed by a flowable CVD method. In some embodiments, thesecond ILD 108 is formed of a dielectric material such as PSG, BSG,BPSG, USG, or the like, and may be deposited by any suitable method,such as CVD and PECVD. The subsequently formed gate contacts 110 (FIGS.20A and 20B) penetrate through the second ILD 108 and the gate mask 106to contact the top surface of the recessed gate electrode 98.

In FIGS. 20A and 20B, gate contacts 110 and source/drain contacts 112are formed through the second ILD 108 and the first ILD 88 in accordancewith some embodiments. Openings for the source/drain contacts 112 areformed through the first and second ILDs 88 and 108, and openings forthe gate contact 110 are formed through the second ILD 108 and the gatemask 106. The openings may be formed using acceptable photolithographyand etching techniques. A liner (not shown), such as a diffusion barrierlayer, an adhesion layer, or the like, and a conductive material areformed in the openings. The liner may include titanium, titaniumnitride, tantalum, tantalum nitride, or the like. The conductivematerial may be copper, a copper alloy, silver, gold, tungsten, cobalt,aluminum, nickel, or the like. A planarization process, such as a CMP,may be performed to remove excess material from a surface of the ILD108. The remaining liner and conductive material form the source/draincontacts 112 and gate contacts 110 in the openings. An anneal processmay be performed to form a silicide at the interface between theepitaxial source/drain regions 82 and the source/drain contacts 112. Thesource/drain contacts 112 are physically and electrically coupled to theepitaxial source/drain regions 82, and the gate contacts 110 arephysically and electrically coupled to the gate electrodes 98. Thesource/drain contacts 112 and gate contacts 110 may be formed indifferent processes, or may be formed in the same process. Althoughshown as being formed in the same cross-sections, it should beappreciated that each of the source/drain contacts 112 and gate contacts110 may be formed in different cross-sections, which may avoid shortingof the contacts.

FIGS. 21A-C through FIGS. 24A-C illustrate intermediate steps in theformation of corner spacers 94 in a first region 150A of a substrate 50and not in a second region 150B of the substrate 50, in accordance withsome embodiments. FIGS. 21A-C illustrate a structure similar to thatshown in FIGS. 14A-C (e.g., after a dielectric layer 92 has beendeposited), except that the substrate 50 has a first region 150A forforming first types of devices (e.g., a core logic region) and a secondregion 150B for forming second types of devices (e.g., an input/outputregion). The first region 150A may be physically separated from thesecond region 150B (as illustrated by divider 151), and any number ofdevice features (e.g., other active devices, doped regions, isolationstructures, etc.) may be disposed between the first region 150A and thesecond region 150B. The first region 150A and/or the second region 150Bmay overlap or may be separate from the n-type region 50N and/or thep-type region 50P. FIGS. 21A, 22A, 23A, and 24A illustratecross-sectional views of the first region 150A and the second region150B along the reference cross-section A-A. FIGS. 21B, 22B, 23B, and 24Billustrate plan views of the first region 150A at the cross-section C-C,and FIGS. 21C, 22C, 23C, and 24C illustrate plan views of the secondregion 150B at the cross-section C-C. In other embodiments, a substrate50 may have more than two regions.

FIGS. 21A-C illustrate the first region 150A and the second region 150Bafter the dielectric layer 92 has been deposited, similar to FIGS.14A-C. FIGS. 21A-C show the devices of the first region 150A and thesecond region 150B as having similar features, but in other embodimentsdifferent regions may have different devices or devices with differingfeatures, and all such variations are considered within the scope of thepresent disclosure.

In FIGS. 22A-C, a masking layer 152 is formed and patterned, inaccordance with some embodiments. The masking layer 152 may be formedover the dielectric layer 92 in the first region 150A and the secondregion 150B. The masking layer 152 may be, for example, a photoresist, aphotoresist structure, or the like, and may be formed using a spin-onprocess or another suitable technique. The masking layer 152 may then bepatterned to expose the first region 150A. The masking layer 152 may bepatterned using acceptable photolithography techniques. As shown inFIGS. 22A-C, the patterned masking layer 152 covers the dielectric layer92 in the second region 150B, including within the recesses 90 of thesecond region 150B.

In FIGS. 23A-C, an etching process is performed to etch the dielectriclayer 92 in the first region 150A, in accordance with some embodiments.The etching process may be similar to that described for FIGS. 16A-C,and accordingly forms corner spacers 94 in the recesses 90 of the firstregion 150A. FIGS. 23A and 23B show the dummy dielectric layer 60 of thefirst region 150A as being etched by the etching process, but in otherembodiments the dummy dielectric layer 60 may be left remaining on thechannel regions 58. As shown in FIGS. 23A and 23C, the masking layer 152covering the second region 150B blocks the dielectric layer 92 of thesecond region 150B from being etched by the etching process.

In FIGS. 24A-C, the masking layer 152 is removed and gate stacks areformed in the first region 150A and in the second region 150B, inaccordance with some embodiments. The masking layer 152 may be removedusing a suitable process, such as an etching process or ashing process.The gate stacks may include a gate dielectric layer 96 and a gateelectrode 98, similar to the gate stacks described for FIGS. 18A-C,which may be formed using suitable techniques such as those describedpreviously. In some embodiments, the gate stacks in the first region150A may be formed simultaneously with the gate stacks in the secondregion 150B. In other embodiments, the gate dielectric layer 96 and/or agate electrode 98 in the first region 150A may be formed before themasking layer 152 is removed, and the gate dielectric layer 96 and/orthe gate electrode 98 in the second region 150B formed after the maskinglayer 152 is removed.

As shown in FIGS. 24A-C, the gate stacks may be formed on the dielectriclayer 92 in the second region 150B. In this manner, the gate dielectriclayers for the devices in the second region 150B may include thedielectric layer 92 and the dummy dielectric layer 60, resulting in thedevice having an effectively thicker gate dielectric layer.Additionally, the presence of the dielectric layer 92 within therecesses 90 can provide additional separation between the gateelectrodes 98 and the epitaxial source/drain regions 82 to reduceleakage or capacitance. In some cases, a thicker gate dielectric layermay be used for relatively higher-power or higher-voltage devices suchas input/output devices or the like. In this manner, the corner spacers94 and thicker gate dielectric layers may be formed for devices inseparate regions, but using some of the same processing steps. Theembodiment described for FIGS. 21A-24C is an example, and othervariations are possible, including additional masking steps, additionaldeposition steps, additional etching steps, or the like.

The disclosed FinFET embodiments could also be applied to nanostructuredevices such as nanostructure (e.g., nanosheet, nanowire,gate-all-around, or the like) field effect transistors (NSFETs). In anNSFET embodiment, the fins are replaced by nanostructures formed bypatterning a stack of alternating layers of channel layers andsacrificial layers. Dummy gate stacks and source/drain regions areformed in a manner similar to the above-described embodiments. After thedummy gate stacks are removed, the sacrificial layers can be partiallyor fully removed in channel regions. In some embodiments, a dielectriclayer similar to the dielectric layer 92 described herein may be formedand etched, with regions of the dielectric layer being incompletelyetched to leave remaining portions similar to the corner spacers 94described herein. The replacement gate structures are formed in a mannersimilar to the above-described embodiments, the replacement gatestructures may partially or completely fill openings left by removingthe sacrificial layers, and the replacement gate structures maypartially or completely surround the channel layers in the channelregions of the NSFET devices. ILDs and contacts to the replacement gatestructures and the source/drain regions may be formed in a mannersimilar to the above-described embodiments. A nanostructure device canbe formed as disclosed in U.S. Patent Application Publication No.2016/0365414, which is incorporated herein by reference in its entirety.

The embodiments described here have some advantages. The techniquesdescribed herein allow for the formation of corner spacers adjacent thegate spacers and the channel region of a fin. The corner spacers may beformed by depositing a dielectric layer after dummy gate removal, andthen controlling an etching of the dielectric layer such that portionsof the dielectric layer remain as the corner spacers. The corner spacersare left in place during formation of the replacement gate stack, whichresults in portions of the replacement gate stack being separated fromthe epitaxial source/drain regions by the corner spacers. Thisadditional separation provided by the corner spacers can reduceparasitic capacitance between the gate stack and the epitaxialsource/drain regions, which can improve high-speed performance of thedevice. Additionally, the use of the corner spacers can reduce currentleakage between the gate stack and the epitaxial source/drain regions.The size or shape of the corner regions can be controlled for aparticular application. Additionally, the use of corner spacers canseparate the gate stack from the epitaxial source/drain regions withoutsignificantly reducing the size of the gate stack. In some cases,masking steps can be used to form corner spacers in separate regions ofa substrate. In some cases, the corner spacers as described herein canbe formed without decreasing the process window for gate stack formationor increasing drain-induced barrier leakage (DIBL) effects. As such, insome cases the corner spacers can achieve the advantages describedherein without significant process changes, device layout changes, orimpact to other areas of device performance.

In accordance with an embodiment, a device includes a fin protrudingfrom a semiconductor substrate; a gate stack over and along a sidewallof the fin; a gate spacer along a sidewall of the gate stack and alongthe sidewall of the fin; an epitaxial source/drain region in the fin andadjacent the gate spacer; and a corner spacer between the gate stack andthe gate spacer, wherein the corner spacer extends along the sidewall ofthe fin, wherein a first region between the gate stack and the sidewallof the fin is free of the corner spacer, wherein a second region betweenthe gate stack and the gate spacer is free of the corner spacer. In anembodiment, the device includes a dummy gate dielectric layer extendingalong the sidewall of the fin, wherein the dummy gate dielectric layeris between the corner spacer and the fin. In an embodiment, the gatestack includes a gate dielectric layer that physically contacts thecorner spacer. In an embodiment, the corner spacer includes siliconoxide, silicon carbide, silicon oxycarbide, silicon oxynitride, siliconoxynitride, or silicon oxycarbonitride. In an embodiment, the cornerspacer extends along the sidewall of the fin a distance that is in therange of 0.5 Å to 600 Å. In an embodiment, the corner spacer has atriangular cross-section in a plan view. In an embodiment, the surfaceof the corner spacer that extends along the sidewall of the gate stackhas a concave profile. In an embodiment, the gate stack includes a gatedielectric and a gate electrode, wherein the gate dielectric physicallycontacts the fin.

In accordance with an embodiment, a device includes a fin over asubstrate; a gate structure on an upper surface and opposing sidewallsof the fin; gate spacers along the opposing sidewalls of the gatestructure, wherein first portions of the gate spacers have a firstwidth, wherein second portions of the gate spacers have a second widththat is greater than the first width, wherein the first portions arecloser to the fin than the second portions, wherein the first width andthe second width are measured in a first direction parallel to asidewall of the fin; a dummy dielectric material on the fin, wherein thedummy dielectric material extends between the fin and the gate spacers;and corner spacers, wherein each of the corner spacers is interposedbetween the gate structure and a corresponding one of the first portionsof the gate spacers. In an embodiment, the second portions of the gatespacers physically contact the gate structure. In an embodiment, a firstportion of the gate structure has a third width, wherein a secondportion of the gate structure has a fourth width that is greater thanthe third width, wherein the first portion of the gate structure iscloser to the fin than the second portion of the gate structure, andwherein the third width and the fourth width are measured in the firstdirection. In an embodiment, the first portions of the gate spacers areseparated by a first distance in the first direction, wherein the firstdistance is greater than the fourth width. In an embodiment, the cornerspacers have convex sidewalls facing the gate structure. In anembodiment, the corner spacer has length measured in a second directionthat is in the range of 0.5 Å to 600 Å, the second direction beingorthogonal to the sidewall of the fin. In an embodiment, a portion ofthe corner spacer that has the largest width in the first directionphysically contacts the dummy dielectric material. In an embodiment, amaterial of the corner spacer is different from the dummy dielectricmaterial.

In an accordance with an embodiment, a method of forming a semiconductordevice includes forming a fin protruding from a substrate; forming adummy gate structure extending over a channel region of the fin; forminga first spacer layer on sidewalls of the dummy gate structure;epitaxially growing source/drain regions on the fin adjacent the channelregion; removing the dummy gate structure to form a recess; depositing asecond spacer layer within the recess; performing an etching process onthe second spacer layer, wherein after performing the etching process,remaining portions of the second spacer layer remain within the recessto form corner spacers, wherein the corner spacers are separated fromeach other, wherein the corner spacers are located at corner regions ofthe recess adjacent the fin; and forming a replacement gate structurewithin the recess and on the corner spacers. In an embodiment, theetching process exposes the channel region. In an embodiment, formingthe replacement gate structure includes depositing a gate dielectricmaterial on the corner spacers and on the channel region in the recess,wherein the gate dielectric material physically contacts the channelregion and the first spacer layer; and depositing a gate electrodematerial on the gate dielectric material. In an embodiment, theremaining portions of the second spacer layer each have a length in arange of 0.5 Å to 600 Å.

The foregoing outlines features of several embodiments so that thoseskilled in the art may better understand the aspects of the presentdisclosure. Those skilled in the art should appreciate that they mayreadily use the present disclosure as a basis for designing or modifyingother processes and structures for carrying out the same purposes and/orachieving the same advantages of the embodiments introduced herein.Those skilled in the art should also realize that such equivalentconstructions do not depart from the spirit and scope of the presentdisclosure, and that they may make various changes, substitutions, andalterations herein without departing from the spirit and scope of thepresent disclosure.

What is claimed is:
 1. A device comprising: a fin protruding from a semiconductor substrate; a gate stack over and along a sidewall of the fin; a gate spacer along a sidewall of the gate stack and along the sidewall of the fin; an epitaxial source/drain region in the fin and adjacent the gate spacer; and a corner spacer between the gate stack and the gate spacer, wherein the corner spacer extends along the sidewall of the fin, wherein the sidewall of the fin is free of the corner spacer, wherein a first region between the gate stack and the sidewall of the fin is free of the corner spacer, wherein a second region between the gate stack and the gate spacer is free of physical contact with the corner spacer, wherein the first region and the second region are laterally adjacent the corner spacer.
 2. The device of claim 1, further comprising a dummy gate dielectric layer extending along the sidewall of the fin, wherein the dummy gate dielectric layer is between the corner spacer and the fin.
 3. The device of claim 1, wherein the gate stack comprises a gate dielectric layer that physically contacts the corner spacer.
 4. The device of claim 1, wherein the corner spacer comprises silicon oxide, silicon carbide, silicon oxycarbide, silicon oxynitride, silicon oxynitride, or silicon oxycarbonitride.
 5. The device of claim 1, wherein the corner spacer extends along the sidewall of the fin a distance that is in the range of 0.5 Å to 600 Å.
 6. The device of claim 1, wherein the corner spacer has a triangular cross-section in a plan view.
 7. The device of claim 1, wherein a surface of the corner spacer that extends along the sidewall of the gate stack has a concave profile.
 8. The device of claim 1, wherein the gate stack comprises a gate dielectric and a gate electrode, wherein the gate dielectric physically contacts the fin.
 9. A device, comprising: a fin over a substrate; a gate structure on an upper surface and opposing sidewalls of the fin; gate spacers along opposing sidewalls of the gate structure, wherein first portions of the gate spacers have a first width, wherein second portions of the gate spacers have a second width that is greater than the first width, wherein the first portions are closer to the fin than the second portions, wherein the first width and the second width are measured in a first direction parallel to a sidewall of the fin; a dummy dielectric material on the fin, wherein the dummy dielectric material extends between the fin and the gate spacers; and corner spacers, wherein each of the corner spacers is interposed between the gate structure and a corresponding one of the first portions of the gate spacers.
 10. The device of claim 9, wherein the second portions of the gate spacers physically contact the gate structure.
 11. The device of claim 9, wherein a first portion of the gate structure has a third width, wherein a second portion of the gate structure has a fourth width that is greater than the third width, wherein the first portion of the gate structure is closer to the fin than the second portion of the gate structure, and wherein the third width and the fourth width are measured in the first direction.
 12. The device of claim 11, wherein the first portions of the gate spacers are separated by a first distance in the first direction, wherein the first distance is greater than the fourth width.
 13. The device of claim 11, wherein the corner spacers have convex sidewalls facing the gate structure.
 14. The device of claim 9, wherein each corner spacer has a length measured in a second direction that is in the range of 0.5 Å to 600 Å, the second direction being orthogonal to the sidewall of the fin.
 15. The device of claim 9, wherein a portion of each corner spacer that has the largest width in the first direction physically contacts the dummy dielectric material.
 16. The device of claim 9, wherein a material of the corner spacers is different from the dummy dielectric material.
 17. A device comprising: a fin protruding from a substrate; a gate structure extending over a channel region of the fin and over a sidewall of the fin; a first spacer material extending over a sidewall of the gate structure and over the sidewall of the fin; a second spacer material adjacent the sidewall of the fin, wherein the second spacer material is at least partially encircled by the sidewall of the fin, the sidewall of the gate structure, and a sidewall of the first spacer material, collectively; a dielectric material on the sidewall of the fin, wherein the dielectric material separates the sidewall of the fin from the first spacer material and the second spacer material; and an epitaxial region on the fin and adjacent the channel region of the fin, wherein the epitaxial region extends farther from the sidewall of the fin than the second spacer material.
 18. The device of claim 17, wherein the second spacer material extends a distance from the dielectric material that is in the range of 0.5 Å to 300 Å.
 19. The device of claim 17, wherein a top surface of the second spacer material is closer to the substrate than a top surface of the gate structure.
 20. The device of claim 17, wherein the dielectric material is a dummy gate dielectric. 